PORTAGE & MAIN BL 2840 User manual

1
Ultimizer Series BL 2840 & BL 3444
PORTAGE & MAIN
WOOD-FIRED OUTDOOR WATER FURNACE
INSTALLATION AND OPERATION MANUAL
PLEASE SAVE THESE INSTRUCTIONS AND REFER TO THEM FOR SAFETY AND
EFFICIENT PREFORMANCE.

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Table of Contents
Page
Letter to Customer ...................................................................................................3
The P & M Outdoor Water Furnace System ................................................................4
Location ..................................................................................................................4
Placement ...............................................................................................................5
Chimney ..................................................................................................................5
Clearances ...............................................................................................................5
Pipe Trench .............................................................................................................5
Water Fill-up.............................................................................................................6
Corrosion Control .....................................................................................................6
Electrical Connections ...............................................................................................7
Starting–Up .............................................................................................................7
Setting ....................................................................................................................7
Operating Instructions ..............................................................................................8
Saving Tips ..............................................................................................................8
Creosote Control ......................................................................................................8
Ash Disposal ............................................................................................................9
Safety Warnings ......................................................................................................9
Maintenance / Fan & Damper Lid Assembly ...........................................................9-10
Connection to Heating System ................................................................................11
Schematic #1 ........................................................................................................12
Schematic #2 ........................................................................................................13
Schematic #3 ........................................................................................................14
Schematic #4 .........................................................................................................15
Wiring Diagram ......................................................................................................16
Controls Functions ............................................................................................. 17-19
Troubleshooting......................................................................................................20
Warranty ................................................................................................................21
Warranty Card ........................................................................................................ 21
Notes & Records ..................................................................................................... 22

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PORTAGE & MAIN WOOD OUTDOOR WATER FURNACE
Manufactured by
Piney Manufacturing Ltd.
Box 130, Piney
R0A 1K0, MB
Canada
Thank you for purchasing a Portage & Main Outdoor Water Furnace which has been tested
and approved by the Canadian Standard Association (CSA MC231278).
Please observe the instructions contained in this Manual and affixed to the unit to enjoy the
full benefits of heating your home, other buildings and your domestic water in a safe and efficient
way. We also recommend that you consult and comply with your local electrical, plumbing and fire
codes, which override these instructions. We have also included some maintenance procedures and
tips that will ensure efficient, economic and trouble-free operation.
For more information regarding the installation, operation and maintenance of this unit, please
contact us or your nearest dealer.
Piney Manufacturing Ltd.

Portage & Main Outdoor Water Furnace Brick Lined BL Ultimizer Series—Wood Burning-- January 2013 Page 4
THE PORTAGE & MAIN OUTDOOR WATER FURNACE
The Portage & Main Outdoor Water Furnace is safe and highly efficient, conveniently installed
outside your house to give you the comfort you desire for your heating season using the oldest
and most environmentally friendly fuel of all: WOOD.
This unique system has a fire pot and heat exchanger which are surrounded with a water
jacket that keeps its components from overheating and warping. The front door is insulated and
built of heavy gauge material to eliminate warping. The multi-pass heat exchanger is designed to
extract useful heat from the flue gases before they exit through the insulated stainless steel
chimney.
The water temperature is maintained at the desired level by aquastats. The heated water is
pumped to the house and the other buildings by means of individual circulating pumps through an
individual underground loop for each building or application.
The heating loop will provide the required amount of heat to your house or building,
regardless of your existing heating systems as described later on. You can also add a water-to-
water heat exchanger to your system to provide you with all your domestic hot water
requirements to increase your fuel savings considerably.
The Portage & Main Outdoor Water Furnace is equipped with a fan for forced combustion air
to modulate the burning rate as required, and with aquastat and hi-limit aquastat which in the
event of failure of the A419 control aquastat, the hi-limit aquastat will prevent the water from
overheating or boiling.
Please follow the instructions contained in this Manual to enjoy the comforts of heating with
wood in a safe manner.
LOCATION
Check with your local jurisdiction codes. In addition to the local codes other consideration may
include:
Outside your residence for safety and lower insurance rates.
In a separate structure such as your garage, shop or shed.
Away from storage of wood, chemicals and other flammable materials.
Downstream of prevailing winds relative to main residence.
On the side of pipe entry to residence.

Portage & Main Outdoor Water Furnace Brick Lined BL Ultimizer Series—Wood Burning-- January 2013 Page 5
RECOMMENDATION
We recommend a hot water circulation loop that will dissipate at least 10% (ten percent) of the
estimated heat output of the water furnace in the event that circulation is reduced because of
electrical power failure. This loop shall be such that it can only be made inoperative by a deliberate
manual action. The minimum pipe to be used should be 18mm (.75 inch) in diameter.
PLACEMENT
We recommend a concrete or cement (noncombustible) slab for placing the P & M Outdoor Water
Furnace. The BL 2840 and BL3440 may be placed with patio bricks or piling or paving stones to
establish a level installation.
CHIMNEY
We recommend the use of insulated stainless steel pipe as a stack to minimize creosote formation. A
six (6) inch pipe is recommended for BL 2840 and an eight (8) inch pipe for BL 3440. The stack
should extend at least four (4) feet above the building where the Outdoor Water Furnace is located.
CLEARANCES
The Outdoor Water Furnace should be placed in a location where it can always get a significant
amount of fresh air. This is important for the water furnace to operate efficiently, and to have good
combustion.
The minimum installation clearances to combustible materials are:
Back & Sides: Twelve (18) inches(46 cm)
Front: Forty-eight (48) inches(122 cm)
Top Eighteen (18) inches(46 cm)
Flue Pipe: Eighteen (18) inches(46 cm)
Note: Adequate space should also be left around the outdoor water furnace in addition to the
required clearances for servicing and maintenance.
PIPE TRENCH
Pre-insulated pipes such as LOGSTOR Dual Pex Flex, properly sized for circulation
requirements are recommended to convey the hot water from the outdoor water furnace to
each building. The piping should be laid in a flat trench eighteen (18) inches to thirty six (36)
inches deep. If high water table is encountered, the trench may be shallower, traffic
permitting. It is to your advantage to be down deeper at the boiler/furnace especially as it
makes the bend easier.
Use of water tight insulation is recommended as all Styrofoam will absorb water to the point it
becomes very poor insulation. Use only in high dry well drained areas if using at all.
All plumbing must be done according to applicable local codes.

Portage & Main Outdoor Water Furnace Brick Lined BL Ultimizer Series—Wood Burning-- January 2013 Page 6
WATER FILL-UP
After installing the P & M Outdoor Water Furnace in place and connecting to it the supply and
return pipe(s) to and from the various buildings to be heated, IN ACCORDANCE WITH
APPLICABLE LOCAL CODES, the heating installation is ready to be filled with water.
Before filling the P & M Outdoor Water Furnace with water, make sure all valves are in
“closed” position, and unused supply and return outlets on the front of the outdoor water
furnace are tightly capped.
A permanent water supply to the Outdoor Water Furnace is recommended by tapping into the
water mains and connecting it to the top of the Outdoor Water Furnace through a manually
operated shut-off valve.
Add water until the entire heating installation is filled and the level gauge on top of the
outdoor water furnace shows full.
Before starting the outdoor water furnace make sure the entire heating installation is properly
vented to facilitate the circulation of water in the heating loop(s).
Ensure water trap and discharge pipe are properly installed and unobstructed to release any
pressure build-up in the outdoor water furnace.
CORROSION CONTROL
To control corrosion in the Portage & Main Outdoor Water Furnace we recommend the following:
1. Always use certified boiler treatment. Submit water sample for testing at initial setup, and
annually through your dealer. Keep your records and submit one copy to Piney Manufacturing
@ 306-922-1662.
2. Always maintain the proper water level.
3. Add a commercially available antifreeze solution to the water in the order of thirty (30) per
cent, during the initial water fill-up. (Optional)
4. When adding large make-up water quantities to compensate for evaporation and to maintain
proper water level, use the same ratio of antifreeze solution to the make-up water. For smaller
make-up water quantities, no antifreeze solution is required.
5. If sedimentation occurs after the initial few weeks, the water should be treated chemically to
adjust its pH level. Consult your dealer for water analysis and treatment.
6. Keep ashes to minimal. Do not burn garbage.
7. Always maintain adequate water level. If level drops occasionally, check for leaks or boiling of
hot water and refer to the Troubleshooting Section.
8. Make sure the outdoor water furnace is properly grounded.
9. Remove ashes when outdoor water furnace is not used
10.Cover the chimney during off-season to prevent rainwater from entering the firepot.
11.Clean the firepot during the off-season.
12.Clean the heat exchanger with the cleaning tool provided with the outdoor water furnace,
through the cleaning door located above the wood-loading door.

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ELECTRICAL CONNECTIONS
The Portage & Main Outdoor Water Furnace is factory-wired and is ready for connecting it to
an AC/120V/60 Hertz supply
ALL ELECTRICAL CONNECTIONS SHALL BE WIRED ACCORDING TO APPLICABLE LOCAL
CODES.
Make sure outdoor water furnace (and metallic water lines, if used) is well grounded to avoid
pitting in the water jacket.
STARTING-UP
Before starting-up observe the SAFETY WARNINGS contained in this Manual.
Make sure the Outdoor Water Furnace, circulating loops and existing heat exchangers or
baseboard heaters are full of water and properly vented.
Ensure the circulating pump(s) is properly installed according to manufacturer’s instructions.
Failure to do so could void the Warranty.
Inspect the chimney and make sure it is clear from any obstructions.
Start the fire with kindling and smaller split wood. DO NOT USE ANY FLAMMABLE LIQUIDS TO
START THE FIRE. Gradually add larger wood to develop an adequate bed of coals. Once a full
coal bed has been developed, the fire may be charged to ultimately last until the next fill time
when there will be a full coal bed to ensure that the added firewood will light.Fill the furnace
regularly to match heat load. Do not overfill your furnace. Put in just enough wood to
maintain temperature until the next fill time usually 12 hours.
Always turn the power off before loading the appliance with wood or opening the firing door.
Keep firing and ash pit doors tightly closed at all times for safety when outdoor water furnace
is in use.
Set the aquastat to the highest temperature setting on the dial (180 F) as described under
SETTING. When the water temperature reaches this set point, the control will turn the
combustion fan off to close the air damper at the bottom of the outdoor water furnace.
When the combustion fan is shut down, turn the setting dial to a range of 175 F to 185F.
Now turn the circulating pump(s) on and leave it on at all times. (180F is ideal operating
temp 175F to 185F are also good; even as high as 195F would be good if required-Consult
with your Portage & Main Furnace Dealer for more info.)
Before leaving the Outdoor Water Furnace location, make sure that:
1. The water level is adequate.
2. The wood loading door is tightly closed.
3. The ash pan door is tightly closed.
4. The area around the outdoor water furnace is clear from any combustible materials.
SETTING
The Portage & Main Outdoor Water Furnace is equipped with a digital display immersion type
aquastat controller which operates in response to water temperature changes.
To set the temperature at the desired level, go to page 17-19 of this manual.

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OPERATING INSTRUCTIONS
1. Portage & Main Outdoor Water Furnace may be connected to an existing boiler system. Burn
natural wood only
2. To avoid damage load wood carefully. Always shut off power before opening firing door or
loading the appliance with wood. Unlatch firing door allow ten seconds for smoke to dissipate
before opening door fully.
3. Do not use chemical substances or liquid fuels to start or enhance the fire.
4. Do not burn garbage, liquid fuels, engine oil, naphtha or other flammable materials, which
may cause a fire or an explosion.
5. Shut off the outdoor water furnace in case of a runway fire.
6. Clean the heat exchanger regularly to remove accumulated creosote and ash. Flue pipe and
chimney need to be cleaned periodically.
7. Clean the Outdoor Water Furnace and cap the chimney at the end of each heating season to
minimize corrosion during summer months.
8. Always maintain the Outdoor Water Furnace, flue pipe and chimney in good condition.
9. Do not load the Outdoor Water Furnace with wood during an electrical power failure. Do not
leave fire door open. Do not use firing, ash or damper doors to manually regulate combustion.
10.For safety do not store any fuel or combustible materials within the installation clearance of
the outdoor water furnace.
11.Keep firing and ash pan doors tightly closed at all times for safety.
12.Always keep the grates at the bottom of the firepot clean and free from ash to allow maximum
combustion air to enter the firepot.
SAVING TIPS
1. Keep the circulating pump(s) on all the time to maintain a comfortable environment and avoid
temperature swings and settling of suspended matter in the water.
2. Maintain a regular wood-loading schedule to keep the Outdoor Water Furnace operating under
steady-state conditions.
3. Turn the circulating pump(s) on occasionally during summer to minimize pump seizure.
CREOSOTE CONTROL
Creosote is formed when wood is burned at a slow rate. Condensation of creosote vapors
occurs in the chimney which is relatively cooler than the Outdoor Water Furnace. This causes
creosote to form a lining inside the chimney.
Accumulations of creosote when ignited may result in chimney fires.
We recommend inspecting the chimney once a month during the heating season and removal
of creosote linings to reduce chimney fire hazards.
Morning high temperature firing of the furnace, for up to ten (10) minutes, twice a week will
eliminate most of the soggy creosote in the heat exchanger and chimney. This is achieved by
opening the ash pan door during the high temperature-firing period. The ash pan door should
be closed immediately after this high temperature firing to prevent overheating of the outdoor
water furnace and water boiling away to an unsafe level.

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ASH DISPOSAL
Ashes should be removed from the Outdoor Water Furnace regularly or they will block the flow
of combustion air from the damper.
Ashes should be stored in metal containers with tight lids and kept in an area free of
combustible materials until finally disposed.
Do not dispose of ashes while embers are still hot.
Check local by-laws for ash disposal. Wood ash can be used to reduce soil acidity or as a
fertilizer for the garden.
SAFETY WARNINGS
Never leave children un-attended near the boiler.
Never add water when outdoor water furnace temperature is close to 212 f as it
may result in steam flashing.
Never perform any service or maintenance work before water temperature drops
below 100 f.
DO NOT store combustible materials or liquids near the Outdoor Water Furnace.
DO NOT burn any materials other than natural wood.
DO NOT use flammable liquids or materials to start or to enhance the fire.
DO NOT leave wood loading door open or unlatched.
DO NOT open the loading door too quickly to avoid blowbacks which could cause sever burns.
ALWAYS check water level, aquastat and damper setting for a proper and safe operation.
DO NOT touch any part on the front of the Outdoor Water Furnace, which is insinuated to
avoid skin burns.
ALWAYS store ashes in tightly covered metal containers away from combustible materials.
Always turn the circulating pump(s) on when burning scraps of wood in the summer to
prevent system from overheating.
MAINTENANCE
Portage & Main Outdoor Water Furnace is designed to operate for many years with the least
amount of maintenance. Good housekeeping practices and observance of the instructions
contained in this Manual would assist you in maintaining the outdoor water furnace in good
and safe working conditions.
ALWAYS SHUT OFF THE POWER SUPPLY prior to performing any service or maintenance work.
Refer to the SAETY WARNINGS and OPERATING INSTRUCTIONS prior to performing any or
maintenance work.
If circulating pump(s) is seized due to a prolonged shutdown, removed the screw in the center
of the motor and turn the motor shaft with a screwdriver to loosen it.

Portage & Main Outdoor Water Furnace Brick Lined BL Ultimizer Series—Wood Burning-- January 2013 Page 10
The damper lid on the blower fan has to be manually adjusted to the desired amount of air required.
This is done simply by moving the air flow adjuster. This blower fan assembly should not be altered
in any way for increased fire.

Portage & Main Outdoor Water Furnace Brick Lined BL Ultimizer Series—Wood Burning-- January 2013 Page 11
CONNECTION TO HEATING SYSTEMS
The P & M Heating System is versatile and can be connected to any existing or new heating system
and/or domestic water system as described below. The corresponding schematics are provided
as a guideline only. ALL CONNECTINS MUST BE EXECUTED ACCORDING TO LOCAL PLUMBING
AND ELECTRICAL CODES.
1. EXISTING FORCED AIR SYSTEM
All you need is to install a water-to-air heat exchanger in your existing furnace plenum (on the
supply side) to keep your house as comfortable as you desire using a separate thermostat. Your
existing furnace would be used as a back up when required. (Refer to Schematic #1)
2. EXISTING WATER BASEBOARD SYSTEM
A water-to-water heat exchanger will be required to replace your existing boiler and provide you
with all the comfort you require. Your existing boiler would be used as a back up when required.
(Refer to Schematic #2). Another alternative would be to convert your existing system into an “open
system” with the assistance of an expert in heating system.
3. NEW WATER BASEBOARD SYSTEM
You will not need any heat exchangers in this case as the Portage and Main Heating System is
directly connected to the baseboard system to keep your house warm and comfortable. (Refer to
Schematic #3)
4. DOMESTIC WTER HEATER AND HEATING SYSTEM
You can enjoy more energy savings and running hot water during the heating season by
connecting your domestic water heater to the Portage & Main Heating System through a sidearm
water heater. (Refer to Schematic #4). We would caution you, however, that creosote may increase
during summer due to lowered heat demand. but if additional heat could be used elsewhere, then
creosote formation would be reduced.

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Side view WaterJacket & FirePot (no insulation shown)

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Wiring Diagram
Ground
Ground
Line 1
Neutral
180
Green
Switch
Fan

18
The A419 control functions
Set point (SP) establishes the temperature value at which the equipment is switched on or
off, depending on the user selected mode of operation. Set point range is -30 to 212˚F or -34 to
100˚C (in 1-degree increments).
If Set point mode is set to cut-in, set point is the temperature value at which the control closes
the Normally Open (N.O.) contacts. If Set point mode is set to cutout, set point is the temperature at
which the N.O. contacts open.
Differential (DIF) established the difference in temperature between the cut-in value and
cutout value. The differential is set relative to Set point and may be set from 1 to 30 F˚ or C˚ (in 1 –
degree increments).
Anti-Short Cycle Delay (ASD) established the minimum time that the outplay relay remains
de-energized before the next on-cycle. The ASDdoes not allow the output relay to re-energize until
the programmed time delay has elapsed. The delay is activated when the control is first turned on
and every time an on-cycle ends. When the delay is activated, the LCD alternately flashed the senor
temperature and ASD. The anti-short Cycle Delay range is 0 to 12 minutes (in 1-minute increments).
Sensor Failure Operation (SF) establishes how the A419 control’s output-relay operates
the equipment in the event of a sensor or sensor wiring failure. The user may select to run the
equipment continuously or to shut it down. When the control detects a sensor circuit failure, the LCD
flashes SF alternately with OP (if the sensor circuit is open), or SH (If the sensor circuit is shorted).
Before indicating a failure, the control implements a 1-minute delay, which allows verification of
failure condition and avoids nuisance failure indications.
Temperature Offset (OFS) establishes a set secondary Set Point and Differential values
that may be invoked to control an application when a circuit is closed between the binary input (BIN)
and common (COM) terminals (and BIN appears on the display). See Figure 3. Offset range is 0 to
50F˚ or C˚ (in 1-degree increments). A typical application might use a switching time clock to invoke
night-setback temperature settings.
IMPORTANT: Make sure the Touchpad Lock jumper is installed (unlocked) before
attempting to adjust the A419 control functions.
Changing the A419 Control Temperature Units
The A419 control is factory set to display Fahrenheit temperature. To change to Celsius, press
Up and Down (arrows) simultaneously. Press them again to display Fahrenheit units. Verify that the
control is displaying the desired temperature units before setting the Set Point.

Portage & Main Outdoor Water Furnace Brick Lined BL Ultimizer Series—Wood Burning-- January 2013 Page 19
Setting the A419 Control Set point Value
To view and adjust Set point, follow these steps:
1. Press and hold MENU (about 2 seconds) until the display flashes SP.
2. Press MENU again to display the existing set point value.
3. Press Up or Down (arrows) to change the set point value.
4. Press MENU again to save the new value. The display returns to the sensed
temperature.
Note: If no setup entry is made for 30 seconds, the control reverts to the (normal)
temperature display.
IMPORTANT: If MENU is not presses after changing the set point value, the control reverts
the preciously programmed set point value.
Figure 6: Liquid Crystal Display, Touchpad, and LED Indicator
Settings on the Other A419 Control Functions
To set the Differential, Anti-short Cycle Delay, Temperature Offset, or Sensor failure operation,
use the following method.
1. Press and hold Menu until the display changes to flashing SP. (This takes about 2
seconds.)
2. Press Up or Down (arrows) repeatedly until the desired function is displayed.
(See Table 3.)
3. Press Menu to display the functions current value.
4. Press Up or Down (arrows) until the desired value is displayed.
5. Press MENU to save the new value. The display returns to the sensor
temperature.
IMPORTANT: If MENU is not pressed after changing the settings, the new settings are no
saved and the control reverts to the previously programmed setting values.
MENU
-10
BIN
F
*
Temperture
Offset Indicator
Temperture
Offset Indicator
Operating Mode
Indicator
Liquid Crystal
Display
Menu Button
Down Arrow
Key
Up Arrow
Key
Output Relay
Status Indicator
LED
*

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NOTE: If no setup entry is made for 30 seconds, the control reverts to the (normal)
temperature display.
NOTE: Any saved A419 control settings are non-volatile and remain in the control’s memory
during power interruptions.
IMPORTANT: Do not set the Set Point and Differential values which (when totaled) fall out
of A419 control’s Set point range (-30 to 212 ˚F [-34 to 100˚C]). The control will not function
properly if Cut-in or Cutout values are outside of the control’s Set point range.
Checkout
Before applying power, make sure installation and wire connections are corrects for your
application. Then power, operate and observe the system and A419 control for at least three
complete operating cycles before leaving the installation.
Table 3: Display Symbols, control Function, Ranges, Unites, Values, and Factory Settings
Display
Symbol
Control
Function
Range –Units/Value
Factory Set
Value
SP
Setpoint*
-30 to 212 - ˚F (-34 to 100 - ˚C)
30
dIF
Differential*
1 to 30 –(F˚ or C˚ in 1-degree
increments)
5
ASD
Anti-short cycle
Delay
0 to 12 –(in 1-minute increments)
1
OFS
Temperature
Offset
0 to 50 (F˚ or C˚ in 1-degree increments)
0
SF
Sensor Failure
Operation
(No range) –0 = output relay de-
energized
1= output relay energized
1
F or C
Temperature
Units
(No range) - F˚ or C˚
F˚
BIN
Temperature
Offset Indicator
(No range) –BIN is displayed and the
A419 control operates on the secondary
setpoints when the circuit between the
BIN and COM terminals is closed.
N/A
Snowflake or
flame picture
Cooling or
Heating Mode of
Operation
(No range) –A Snowflake (Cooling Mode)
is displayed when the Jump1 jumper is
removed. A Flame (Heating Mode) is
displayed when the Jump1 jumper is
installed.
Snowflake
(Cooling Mode)
*The sum of the Set Point and Differential values must be within the Set Point range, or the
control may not function properly.